US7765848B2 - Press working method and press working apparatus - Google Patents

Press working method and press working apparatus Download PDF

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Publication number
US7765848B2
US7765848B2 US11/733,427 US73342707A US7765848B2 US 7765848 B2 US7765848 B2 US 7765848B2 US 73342707 A US73342707 A US 73342707A US 7765848 B2 US7765848 B2 US 7765848B2
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United States
Prior art keywords
die
press
steel plate
holder
slider
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US11/733,427
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US20070240479A1 (en
Inventor
Yuichi Nagai
Hideo Meguri
Kenzo Takeda
Takayuki Egawa
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Honda Motor Co Ltd
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Honda Motor Co Ltd
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Priority claimed from JP2006112256A external-priority patent/JP4804207B2/ja
Priority claimed from JP2006112242A external-priority patent/JP2007283333A/ja
Application filed by Honda Motor Co Ltd filed Critical Honda Motor Co Ltd
Assigned to HONDA MOTOR CO., LTD. reassignment HONDA MOTOR CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: EGAWA, TAKAYUKI, MEGURI, HIDEO, NAGAI, YUICHI, TAKEDA, KENZO
Publication of US20070240479A1 publication Critical patent/US20070240479A1/en
Priority to US12/833,357 priority Critical patent/US7963141B2/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B30—PRESSES
    • B30B—PRESSES IN GENERAL
    • B30B15/00—Details of, or accessories for, presses; Auxiliary measures in connection with pressing
    • B30B15/14—Control arrangements for mechanically-driven presses
    • B30B15/148—Electrical control arrangements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
    • B21D22/20—Deep-drawing
    • B21D22/22—Deep-drawing with devices for holding the edge of the blanks
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D24/00—Special deep-drawing arrangements in, or in connection with, presses
    • B21D24/10—Devices controlling or operating blank holders independently, or in conjunction with dies
    • B21D24/14—Devices controlling or operating blank holders independently, or in conjunction with dies pneumatically or hydraulically
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D37/00—Tools as parts of machines covered by this subclass
    • B21D37/08—Dies with different parts for several steps in a process

Definitions

  • the present invention is related to a press working method and a press working apparatus in which a press-formed product is worked by a servo press.
  • a servo press which can flexibly control a motion of a die with a servo motor. Concerning this matter, refer to JP-A-2001-150200 and JP-B2-3537287. In this type servo press, it is possible to stop the die at a predetermined position in the middle of one stroke in which the die is moved upward and downward.
  • the steel plate is lightly pushed by a blank corresponding to the holder. Therefore, at the time of working, the steel plate is drawn inside a die. That is, the steel plate is not continuously pushed by the blank at all times. Accordingly, it is possible to somewhat prevent wrinkles from being generated. It is also possible to somewhat prevent small wall thickness portions from being generated.
  • JP-A-2005-199318 The method described in JP-A-2005-199318 is applied on the assumption that almost all the steel plate is drawn inside the die being slid on the die at the time of working. Therefore, it is necessary that a pushing force given by the blank is finely adjusted according to the shape of the formed product and the material and the surface roughness of the steel plate. Further, an operator must be sufficiently experienced in selecting appropriate lubricant for press forming.
  • One or more embodiments of the present invention provide a press working method and a press working apparatus capable of effectively conducting press working on a plate a plurality of times in a short period of working time.
  • a press working method of working a press-formed product with a servo press is provided with: a press forming step of conducting press forming on a plate when a first die is made to come close to a second die; a punch protruding step in which the first die is separated from the second die and a movable punch is protruded from the first die toward the second die and locked; and an additional forming step in which the first die is again made to come close to the second die after the completion of the punch protruding step and the plate, which has already been pressed, is pressed by the first die and a portion of the plate is pushed and deformed by the movable punch.
  • a press forming step which is an additional working step, can be conducted again on the plate on which the press forming of the first time has already been completed.
  • a press working apparatus in which servo press control is conducted, is provided with: a movable punch provided in a first die and capable of protruding from a press forming face; and a lock means for locking the movable punch at a position protruding from the press forming face, wherein after the first die has been made to come close to the second die and a plate has been pressed, the first die is separated from the second die and the movable punch is protruded from the first die toward the second die and locked by the lock means, the first die is again made to come close to the second die so as to push the plate, which has already been subjected to press forming, with the first die and push and deform a portion of the plate with the movable punch.
  • a press forming step which is an additional working step, can be conducted again on the plate on which the first time press forming has already been completed.
  • the first die is separated from the second die and then the movable punch is protruded and locked and further the first die is again made to come close to the second die. Due to the foregoing, without using another independent working means, a press forming step can be conducted again on the plate on which the first time press forming has already been completed.
  • the entire apparatus can be made compact. Therefore, a space for installing the apparatus can be made small. Further, only when the movable punch is protruded from the first die and locked, press forming of the second time can be prepared. Therefore, a plurality of press forming steps can be effectively conducted on a plate in a short period of time.
  • press working can be conducted twice by one press working apparatus, it is unnecessary to convey a plate between the apparatus.
  • one or more embodiments of the present invention provide a press forming method and a press forming apparatus, which can be suitably applied to working of a steel plate except for deep drawing, in which it is possible to prevent wrinkles from being generated and further it is possible to prevent small wall thickness portions from being generated.
  • a press working method of working a press-formed product with a servo press is provided with: a press forming step in which a plate is pressed when a first die is made to come close to a second die while the plate is being pinched by a first and a second holder; and a pinch release means for releasing a pinch conducted by the first and the second holder on the plate after press forming of the plate was started in the press forming step and before both the dies reach a bottom dead center at which the dies are made to come close to each other.
  • the plate when a pinch made by the first and the second holder is released before the first and the second holder reach the bottom dead center at which both the dies are made to come close to each other, the plate can be moved. Accordingly, it is possible to prevent wrinkles, which are generated when the plate is excessively strongly stretched, from being generated. Further, it is possible to prevent small wall thickness portions, which are generated when the plate is excessively strongly stretched, from being generated.
  • the paragraph “before the first and the second holder reach the bottom dead center” includes the meaning that the first and the second holder have reached the bottom dead center.
  • control operation time in the pinch release step is set by a controller for controlling the first die so that the first die can be made to come close to the second die.
  • a press working apparatus in which servo press control is conducted, is provided with: a first and a second die for conducting press forming on a plate; a first holder provided in the first die; a second holder, which is provided at a position opposed to the first holder, for pinching the plate together with the first holder; and a controller for advancing and retracting the second holder, wherein at the time of press forming step in which the plate is pressed when the first die is made to come close to the second die, while the plate is being pinched by the first and the second holder, after press forming of the plate was started and before the first and the second holder reach a bottom dead center at which both the dies are made to come close to each other, the controller releases the plate which are pinched by the first and the second holder.
  • the plate when a pinch made by the first and the second holder is released before the first and the second holder reach the bottom dead center at which both the dies are made to come close to each other, the plate can be moved. Accordingly, it is possible to prevent wrinkles, which are generated when the plate is excessively strongly stretched, from being generated. Further, it is possible to prevent small wall thickness portions, which are generated when the plate is excessively strongly stretched, from being generated.
  • the plate is positively pinched between the first and the second holder. Therefore, positioning can be accurately made and it is possible to prevent wrinkles from being generated at the initial stage of working. Further, operation of pinching and releasing the plate by the first and the second holder can be sufficiently conducted by ON-OFF control and it is unnecessary to give consideration to a slide of the plate. Accordingly, it is not needed to adjust a pushing force. Further, lubricant is not particularly needed. Therefore, operation can be performed simply.
  • the method and apparatus of the present invention can be suitably applied to press working except for deep drawing.
  • FIG. 1 is a schematic illustration showing an arrangement of the press working apparatus of a first exemplary embodiment.
  • FIG. 2 is an enlarged view showing an additional working machine in a state in which a movable punch is retracted.
  • FIG. 3 is an enlarged view showing an additional working machine in a state in which a movable punch is protruded.
  • FIG. 4 is a block arrangement diagram showing a press drive portion and a die cushion drive portion.
  • FIG. 5 is a flow chart (1) showing a procedure of the press working method of the first exemplary embodiment.
  • FIG. 6 is a flow chart (2) showing a procedure of the press working method of the first exemplary embodiment.
  • FIG. 7 is a partially sectional enlarged view showing an upper die, a lower die, an additional worked portion of a steel plate and an additional working portion in the case where a slider is stopped at a bottom dead center.
  • FIG. 8 is a partially sectional enlarged view showing an upper die, a lower die, an additional worked portion of a steel plate and an additional working portion in the case where a slider is raised to a movable punch preparation position and the movable punch is protruded and locked.
  • FIG. 9 is a partially sectional enlarged view showing a state in which a slider is lowered again to a bottom dead center from the state shown in FIG. 8 .
  • FIG. 10 is a partially sectional enlarged view showing a state in which a movable punch is retracted from the state shown in FIG. 9 .
  • FIG. 11 is a schematic illustration showing an apparatus body in a state in which a rise in a blank holder is temporarily stopped at a panel conveyance position.
  • FIG. 12 is a perspective view showing a sheet metal member of a trunk portion of a vehicle.
  • FIG. 13A is a graph showing a displacement of a slider in one cycle
  • FIG. 13B is a graph showing a displacement of a blank holder in one cycle
  • FIG. 13C is a graph showing a displacement of a movable punch in one cycle.
  • FIG. 14 is a schematic illustration showing an arrangement of the press working apparatus of a second exemplary embodiment.
  • FIG. 15 is a block arrangement diagram showing a press drive portion and a die cushion drive portion.
  • FIG. 16 is a flow chart showing a procedure of the press working method of the second exemplary embodiment.
  • FIG. 17 is a partially sectional view showing an upper die, lower die, holder and blank holder at the time of an arrival of a blank holder at a pinch release position.
  • FIG. 18 is a partially sectional view showing an upper die, lower die, holder and blank holder at the time of an arrival of a slider at a bottom dead center.
  • FIG. 19 is a schematic illustration of a press forming apparatus in a state in which a rise of a blank holder is temporarily stopped at a panel conveyance position.
  • FIG. 20A is a graph showing a displacement of a slider in one cycle and FIG. 20B is a graph showing a displacement of a blank holder in one cycle.
  • press working method and the press working apparatus of a first exemplary embodiment of the present invention will be explained, referring to FIGS. 1 to 13C .
  • press working apparatus 10 of the first exemplary embodiment after press working of the first time has been conducted on a steel plate (plate member) 12 which is a workpiece, press working of the second time, which is an additional working, is conducted.
  • the press working apparatus 10 includes: an apparatus body 14 for conducting working; and a control portion 16 for controlling the apparatus body 14 .
  • the apparatus body 14 includes: an upper die mechanism 18 ; a lower die mechanism 20 ; and an additional working portion 22 provided inside the upper die mechanism 18 .
  • the upper die mechanism 18 includes: a servo motor 24 which is a drive source; a reduction gear 26 driven and rotated by the servo motor 24 ; a rotary plate 28 driven and rotated by the reduction gear 26 at high torque; and a connecting rod 30 , the upper end portion of which is pivotally attached onto a side of the rotary plate 28 so that the connecting rod 30 can be oscillated.
  • the servo motor 24 is, for example, of the AC type. Therefore, the responding property of the servo motor 24 is high and torque generated by the servo motor 24 seldom deviates.
  • a rotary position of the shaft of the servo motor 24 is detected by an encoder 24 a and sent to the control portion 16 .
  • the upper die mechanism 18 includes: a slider 32 pivotally supported by an end portion of the connecting rod 30 ; a plurality of rails 34 (for example, four rails 34 ) to guide the slider 32 in the vertical direction; a first linear sensor 36 to detect a position of the slider 32 and sent it to the control portion 16 ; and an upper die (a first die) 38 provided on a lower face of the slider 32 .
  • the upper die 38 pinches a steel plate 12 together with a lower die (a second die) 52 so as to conduct press working.
  • a die face 38 a is provided which comes into contact with an upper face of the steel plate 12 .
  • an annular holder 40 is provided being a little protruded which is used for preventing the generation of wrinkles on the steel plate 12 and for preventing the occurrence of a positional deviation of the steel plate 12 at the time of press forming. Accordingly, the holder 40 comes into contact with the steel plate 12 before the die face 38 a .
  • a lower face of the holder 40 is formed into a shape corresponding to the forming shape, for example, the lower face of the holder 40 is formed into a horizontal face.
  • the upper die 38 includes an additional working portion 22 .
  • the additional working portion 22 is provided for the following reasons. After the press working of the first time has been conducted on the steel plate by the upper die mechanism 18 and the lower die mechanism 20 , the additional working portion 22 conducts the press working of the second time so as to conduct an additional working on the steel plate.
  • the additional working portion 22 includes: a movable punch 90 capable of protruding from the die face 38 a ; a spring 91 for pushing the movable punch 90 so that the movable punch 90 can be retracted from the die face 38 a ; a driver rod 92 for protruding the movable punch 90 from the die face 38 a when the driver rod 92 slides on an inclined face of the movable punch 90 ; an actuator 93 for pushing out the driver rod 92 ; and a mechanical lock 94 for locking the driver rod 92 when the mechanical lock 94 is engaged in a cutout portion 92 a formed on the driver rod 92 which has been pushed out.
  • the mechanical lock 94 is advanced and retracted in a direction perpendicular to the advancing and retracting direction of the driver rod 92 (the lateral direction in FIG. 2 ) when a predetermined actuator (not shown), which pushes out the mechanical rod 94 , is operated. Therefore, the mechanical lock 94 can be attached in and detached from the cutout portion 92 a .
  • An example of the actuator 93 is a cylinder.
  • the movable punch 90 is engaged in a guide hole 38 b provided in the upper die 38 .
  • the movable punch 90 can be advanced and retracted in an oblique direction as shown in FIG. 2 , the inclination angle of which is approximately 45°.
  • a chamfered portion 90 a is provided in the periphery of the forward end portion of the movable punch 90 .
  • the movable punch 90 is given a force by an elastic action of the spring 91 so that the movable punch 90 can be retracted into the guide hole 38 b . Accordingly, the driver rod 92 is moved to the right in FIG. 2 . The driver rod 92 is moved until a protruding portion 92 b of the driver rod 92 comes into contact with a step portion 95 of the upper die 38 . At this time, a forward end face 90 b of the movable punch 90 is set on the same face as the die face 38 a . In the case where the die face 38 a is a curved face, the forward end face 90 b of the movable punch 90 is formed into the same curved face.
  • the movable punch 90 proceeds resisting an elastic force of the spring 91 . Therefore, a forward end face 90 b of the movable punch 90 protrudes from the die face 38 a by width H.
  • the mechanical lock 94 is engaged in the cutout portion 92 a and locks the driver rod 92 , so that the movable punch 90 can be fixed.
  • An object to be locked by the lock means such as a mechanical lock 94 is not necessarily limited to the driver rod 92 but the movable punch 90 may be locked.
  • an amount of the downward protrusion of the movable punch 90 from the die face 38 a is represented by xh.
  • the lower die mechanism 20 includes: a fixation table 50 which is used as a base; a lower die 52 arranged in an upper portion of the fixation table 50 ; an annular blank holder 54 for supporting a periphery of the steel plate 12 ; and a die cushion mechanism 56 for elevating a blank holder 54 .
  • the blank holder 54 is arranged being opposed to the holder 40 . Therefore, the blank holder 54 pinches an end portion of the steel plate 12 together with the holder 40 .
  • the lower die 52 is used for press working when it pinches the steel plate 12 together with the upper die 38 .
  • a die face 52 a is provided which comes into contact with a lower face of the steel plate 12 .
  • This die face 52 a is formed into a shape corresponding to the aforementioned die face (the press forming face) 38 a .
  • a recess portion 58 is provided at a position corresponding to the additional worked portion 12 a (shown in FIG. 7 ) which conducts an additional working on the steel plate 12 after the completion of the press working of the first time.
  • This recess portion 58 An area of this recess portion 58 is set so that the movable punch 90 can push the steel plate 12 into the recess portion 58 and conduct press forming.
  • a depth of the recess portion 58 is set at a value so that the steel plate 12 can be pinched by the front end face 90 b and the bottom face 58 a of the recess portion 58 when the movable punch 90 is inserted into the recess portion 58 .
  • the die cushion mechanism 56 includes: a plurality of pins 60 which penetrate the fixation table 50 and the attaching portion 52 b of the lower die 52 from the lower side and are fixed in a lower portion of the blank holder 54 ; a plate 62 for connecting lower end portions of these pins 60 ; a plurality of cylinders 64 for elevating the plate 62 ; and a second linear sensor 66 for detecting a position of the plate 62 and sending a signal of the position of the plate 62 to the control portion 16 .
  • the die cushion mechanism 56 includes: a hydraulic motor 68 for supplying hydraulic fluid to the cylinders 64 and for recovering hydraulic fluid from the cylinders 64 ; and a servo motor 70 for rotating the hydraulic motor 68 .
  • Rotation of the servo motor 70 is transmitted to the hydraulic motor 68 through a transmission portion 72 including a coupling, a reduction gear and so forth.
  • the hydraulic motor 68 is rotated either normally or reversely being driven by the servo motor 70 . Therefore, it is possible for the hydraulic motor 68 to selectively supply hydraulic fluid to the rod side or the cap side of the cylinder 64 . Due to the above constitution, while predetermined pressure control is being conducted, the periphery of the steel plate 12 is appropriately pushed by both the holder 40 and the blank holder 54 . Therefore, the generation of wrinkles can be prevented.
  • the control portion 16 includes: a press drive portion 16 a for driving and controlling the servo motor 24 while referring to signals sent from the encoder 24 a and the first linear sensor 36 ; an additional working machine drive portion 16 b for driving and controlling the actuator 93 and the mechanical lock 94 ; and a die cushion drive portion 16 c for elevating the blank holder 54 by driving the servo motor 70 while referring to a signal sent from the second linear sensor 66 .
  • the press drive portion 16 a , the additional working machine drive portion 16 b and the die cushion drive portion 16 c are connected with each other. Therefore, the press drive portion 16 a , the additional working machine drive portion 16 b and the die cushion drive portion 16 c can be operated synchronously with each other.
  • the press drive portion 16 a includes: a servo power source portion 104 to which electric power obtained from an electric power source 100 is supplied after the voltage has been raised by a transformer 102 ; and a servo amplifier 106 for driving the servo motor 24 with electric power adjusted by the servo power source portion 104 .
  • a servo amplifier 106 for driving the servo motor 24 with electric power adjusted by the servo power source portion 104 .
  • an amount of driving of the servo amplifier 106 is set while the software functional portion 108 is acting.
  • a large capacity condenser 110 is provided between the servo power source portion 104 and the servo amplifier 106 .
  • the die cushion drive portion 16 c includes: a servo power source portion 112 to which electric power is supplied from the power source 100 ; and a servo amplifier 114 for driving the servo motor 70 with electric power adjusted by the servo power source portion 112 .
  • An amount of driving of the servo motor 70 is set by the servo amplifier 114 while the software functional portion 116 is acting.
  • An electric current can be made to flow in both the positive and the negative direction in the servo power source portion 112 and the servo amplifier 114 .
  • the servo motor 70 is rotated by a load and generates electricity, it is possible to conduct a regeneration of electric power in which an electric current obtained by the generation of electric power is supplied to the press drive portion 16 a .
  • the thus regenerated electric power is stored in the large capacity condenser 110 and used for driving the servo motor 24 . Therefore, an increase in the power source capacity can be suppressed.
  • initial setting is made in step S 1 in FIG. 5 . That is, after the blank holder 54 has been raised to a predetermined position, the steel plate 12 , which has not been worked yet, is supported by the blank holder 54 . In the additional working portion 22 , the actuator 93 is retracted and the upper die 38 is raised to an upper dead center.
  • step S 2 while the press drive portion 16 a is acting, the servo motor 24 is driven and rotated so as to lower the slider 32 .
  • the blank holder 54 When the slider 32 is somewhat lowered, the holder 40 comes into contact with an upper face of the steel plate 12 . Therefore, the steel plate 12 is interposed between the holder 40 and the blank holder 54 .
  • the blank holder 54 is lowered while the die cushion drive portion 16 c is acting (step S 3 ).
  • the die cushion drive portion 16 c conducts pressure control so that the blank holder 54 can be lowered while the steel plate 12 is positively being held by an appropriate force generated by the blank holder 54 when a lower face of the steel plate 12 is pushed by the blank holder 54 . That is, the blank holder 54 is pushed by the holder 40 via the steel plate 12 . Therefore, the blank holder 54 is lowered while the steel plate 12 is being given an appropriate force.
  • the steel plate 12 is gradually pressed to a product shape by the upper die 38 and the lower die 52 .
  • the aforementioned regeneration may be made when electric power is generated by the servo motor 70 .
  • step S 4 according to a signal sent from the first linear sensor 36 , the press drive portion 16 a confirms whether or not a position of the slider 32 has reached the bottom dead center (that is, the lowest position during one stroke of the upper die 38 ).
  • the program proceeds to step S 5 .
  • the slider 32 continues to be lowered.
  • step S 5 operation of lowering the slider 32 and the blank holder 54 is temporarily stopped. At this time, as shown in FIG. 7 , the steel plate 12 is pinched between the die face 38 a of the upper die 38 and the die face 52 a of the lower die 52 and press working has already been completed.
  • step S 6 while the press drive portion 16 a is acting, the servo motor 24 is driven and rotated so as to raise the slider 32 .
  • step S 7 it is confirmed whether or not the slider 32 has been raised to a predetermined position at which the movable punch is ready for punching operation.
  • the program proceeds to step S 8 .
  • the slider 32 continues to be raised.
  • step S 8 while the press drive portion 16 a is acting, the servo motor 24 is stopped so as to stop the slider 32 at the movable punch preparation position.
  • the movable punch preparation position may be any position as long as the movable punch 90 can be protruded at the position.
  • the movable punch preparation position is a position sufficiently lower than displacement x 3 at the point of time when the holder 40 comes into contact with an upper face of the steel plate 12 in step S 3 described before. Concerning this matter, refer to FIG. 13A .
  • distance xp from the bottom dead center to the movable punch preparation position is approximately 1 to 5 times as long as an amount of the downward protrusion xh (shown in FIG. 3 ) of the movable punch 90 . It is more preferable that distance xp from the bottom dead center to the movable punch preparation position is approximately 1.1 to 3 times as long as the amount of the downward protrusion xh.
  • distance xp is set as described above, the movable punch 90 can be positively protruded. Further, a period of time necessary for raising the slider 32 can be reduced. Accordingly, the cycle time can be shortened.
  • step S 9 the punch protruding step
  • the driver rod 92 is protruded via the actuator 93 . Due to this operation, a forward end face 90 b of the movable punch 90 can be protruded from the die face 38 a by width H as shown in FIG. 3 .
  • the slider 32 is raised to the movable punch preparation position. Therefore, the movable punch 90 can be positively protruded. Since no load is given to the movable punch 90 , the movable punch 90 can be protruded by a weak force. Therefore, it is sufficient to use an actuator 93 , the capacity of which is small. For example, it is sufficient to use a pneumatic cylinder.
  • the driver rod 92 is set in such a manner that when the driver rod 92 is advanced at the maximum while the actuator 93 is acting, the forward end face 90 b of the movable punch 90 is protruded from the die face 38 a by width H.
  • the driver rod 92 may be controlled as follows. When a linear sensor or a limit switch is provided and an advancing distance of the driver rod 92 is referred, the driver rod 92 is stopped when it is advanced at an appropriate position.
  • step S 10 the punch protrusion step
  • the mechanical lock 94 is driven so as to engage the mechanical lock 94 with the cutout portion 92 a of the driver rod 92 , and the driver rod 92 and the movable punch 90 are locked with each other.
  • the mechanical lock 94 may be driven by a drive system of ON and OFF conducted by a solenoid. Alternatively, when a linear sensor or a limits witch is provided, an amount of advancement of the mechanical lock 94 may be controlled by the linear sensor or the limit switch.
  • step S 11 (the additional forming step) shown in FIG. 6 , while the press drive portion 16 a is acting, the servo motor 24 is driven and rotated so as to lower the slider 32 again.
  • step S 12 the additional forming step
  • the press drive portion 16 a confirms whether or not the slider 32 has reached the bottom dead center while referring to a signal sent from the first linear sensor 36 .
  • the program proceeds to step S 13 .
  • the slider 32 is continuously lowered.
  • step S 13 (the additional forming step) a descent of the slider 32 and a descent of the blank holder 54 are temporarily stopped.
  • the steel plate 12 which has already been press-formed, is pushed by the upper die 38 and the lower die 52 .
  • the movable punch 90 is inserted into the recess portion 58 , the additional worked portion 12 a is pushed and deformed.
  • the movable punch 90 receives a reaction force.
  • press forming can be stably conducted.
  • step S 14 while the additional working machine drive portion 16 b is acting, the mechanical lock 94 is driven so as to draw it out from the cutout portion 92 a of the driver rod 92 . That is, the driver rod 92 and the movable punch 90 are unlocked.
  • step S 15 as shown in FIG. 10 , while the additional working machine drive portion 16 b is acting, the drive rod 92 is retracted through the actuator 93 and moved until the protrusion 92 b comes into contact with the step portion 95 of the upper die 38 . Due to the above operation, while the spring 91 is exhibiting an elastic action, the movable punch 90 is retracted to a position where the front end face 90 b of the movable punch 90 is located on the same face as the die face 38 a.
  • step S 16 while the press drive portion 16 a is acting, the servo motor 24 is driven and rotated to raise the slider 32 . At the same time, while the die cushion drive portion 16 c is acting, the blank holder 54 is raised. At this point of time, the blank holder 54 is left being stopped.
  • step S 17 it is confirmed whether or not the slider 32 has reached a panel conveyance position.
  • the program proceeds to step S 18 .
  • the slider 32 continues to be raised.
  • step S 18 while the die cushion drive portion 16 c is acting, the blank holder 54 is raised. Due to this operation, the blank holder 54 is raised a little later than the slider 32 .
  • step S 19 the die cushion drive portion 16 c confirms whether or not the blank holder 54 has reached the panel conveyance position.
  • the program proceeds to step S 20 .
  • the blank holder 54 continues to be raised.
  • step S 20 as shown in FIG. 11 , a rise of the blank holder 54 is temporarily stopped and the steel plate 12 , which has already been subjected to press working and additional working, is conveyed to the next step, for example, a welding step by a predetermined conveyance means.
  • step S 21 the die cushion drive portion 16 c raises the blank holder 54 again.
  • step S 22 the die cushion drive portion 16 c confirms whether or not the blank holder 54 has reached a working wait position.
  • the program proceeds to step S 23 .
  • the blank holder 54 continues to be raised.
  • step S 23 a rise of the blank holder 54 is stopped and the steel plate 12 , which has not been worked yet, is arranged at a predetermined position. In this connection, even in this period of time, the slider 32 continues to be raised.
  • step S 24 the press drive portion 16 a confirms whether or not the slider 32 has reached the top dead center referring to a signal sent from the first linear sensor 36 .
  • the slider 32 has not reached the top dead center, it continues to be raised.
  • the processing of this time shown in FIGS. 5 and 6 is completed.
  • the slider 32 may be temporarily stopped for maintaining an appropriate relation with the cycle time of the other step. In the case where no influence is given to the other step, the slider 32 may not be temporarily stopped and the next steel plate 12 may be continuously worked.
  • the press drive portion 16 a , the additional working machine drive portion 16 b and the die cushion drive portion 16 c may be independently operated while the mutual synchronization is being confirmed among them.
  • the trunk portion sheet metal 140 for a vehicle shown in FIG. 12 can be press-formed.
  • the bent portion 140 a which is located on the boundary between the upper face and the rear face, is worked by the press forming of the first time.
  • the dent portion 140 b to which a license plate is attached, is worked by the press forming of the second time.
  • the above dent portion 140 b can not be formed by a conventional press working method and press working apparatus. Therefore, it is conventional that another part is attached at a position where the dent portion is to be formed.
  • the press working method and the press working apparatus 10 of the first exemplary embodiment it is possible to form the dent portion 140 b out of one steel plate 12 . Therefore, the number of parts and the number of man-days necessary for assembling can be reduced.
  • a series of the above working cycle is expressed by the time charts shown in FIGS. 13A to 13C .
  • the step numbers in the above processing are attached to corresponding portions.
  • displacement x of the slider 32 changes as follows. Displacement x of the slider 32 changes from top dead center x 1 to bottom dead center x 2 . Then, displacement x of the slider 32 once returns by displacement xp. After the processing of protruding and locking of the movable punch 90 (steps S 9 and S 10 ), displacement x of the slider 32 reaches bottom dead center x 2 again. After the completion of step S 18 , displacement x of the slider 32 returns to top dead center x 1 again. At the time corresponding to step S 3 , displacement x of the slider 32 reaches displacement x 3 at which the holder 40 comes into contact with an upper face of the steel plate 12 . Displacement x 4 at the point of time of step S 18 is a panel conveyance position. That is, displacement x 4 at the point of time of step S 18 is a position corresponding to displacement y 3 of the blank holder 54 .
  • displacement y of the blank holder 54 stops at working wait position y 1 in the period of time corresponding to steps S 1 to S 3 and in the period of time after step S 23 .
  • displacement y of the blank holder 54 stops at the position of displacement y 2 .
  • the blank holder 54 ascends and descends at the substantially same speed as that of the slider 32 .
  • the blank holder 54 stops at panel conveyance position y 3 .
  • displacement z of the movable punch 90 stops at wait position z 1 in the periods of time between steps S 1 and S 9 and after step S 15 .
  • the movable punch 90 starts protruding in step S 9 right after step S 8 and is displaced by width H. After that, the movable punch 90 returns to wait position z 1 in step S 15 .
  • the upper die 38 is separated from the lower die 52 and the movable punch 90 is protruded and locked and then the upper die 38 is made to come close to the lower die 52 again. Due to the above operation, without using another independent working means, the steel plate 12 , on which press forming of the first time has already been completed, can be subjected to press forming again.
  • the movable punch 90 is provided in the upper die 38 , the entire press working apparatus can be made compact. Therefore, an installation space can be reduced. Further, only when the movable punch 90 is protruded from the upper die 38 and locked, a preparation of press forming of the second time is completed. Therefore, it is possible to effectively conduct press forming a plurality of times on the steel plate 12 in a short period of time of working. Further, since working can be conducted twice by one press working apparatus 10 , no labor is required for conveying the steel plate 12 between the apparatus.
  • the time of conducting the step in which the movable punch 90 is protruded and the time of operating the additional working portion 22 are set by the control portion 16 which conducts controlling of making the upper die 38 come close to the lower die 52 . Therefore, the movable punch 90 can be accurately synchronized with the press working.
  • a press working method and a press working apparatus according to a second exemplary embodiment of the present invention will be explained, referring to FIGS. 14 to 20B .
  • press working of a steel plate 212 which is a workpiece, is conducted.
  • the press working apparatus 210 is provided with: an apparatus body 214 for conducting working; and a control portion 216 for controlling the apparatus body 214 .
  • the apparatus body 214 is provided with: an upper die mechanism 218 ; and a lower die mechanism 220 .
  • the upper die mechanism 218 is provided with: a servo motor 224 which is a drive source; a reduction gear 226 driven and rotated by the servo motor 224 ; a rotary plate 228 driven and rotated by the reduction gear 226 at high torque; and a connecting rod 230 , the upper end portion of which is pivotally attached onto a side of the rotary plate 228 so that the connecting rod 230 can be oscillated.
  • the servo motor 224 is, for example, of the AC type. Therefore, the responding property of the servo motor 224 is high and torque generated by the servo motor 224 seldom deviates.
  • a rotary position of the shaft of the servo motor 224 is detected by an encoder 224 a and sent to the control portion 216 .
  • the upper die mechanism 218 includes: a slider 232 pivotally supported by an end portion of the connecting rod 230 ; a plurality of rails 234 (for example, four rails 234 ) to guide the slider 232 in the vertical direction; a first linear sensor 236 to detect a position of the slider 232 and sent it to the control portion 216 ; and an upper die (a first die) 238 provided on a lower face of the slider 232 .
  • the upper die 238 pinches a steel plate 212 together with a lower die (a second die) 252 so as to conduct press working.
  • a die face 238 a is provided which comes into contact with an upper face of the steel plate 212 .
  • an annular holder (a first holder) 240 is provided being a little protruded which is used for preventing the generation of wrinkles on the steel plate 212 and for preventing the occurrence of a positional deviation of the steel plate 212 at the time of press forming. Accordingly, the holder 240 comes into contact with the steel plate 212 before the die face 238 a .
  • a lower face of the holder 240 is formed into a shape corresponding to the forming shape, for example, the lower face of the holder 240 is formed into a horizontal face.
  • the lower die mechanism 220 includes: a fixation table 250 which is used as a base; a lower die 252 arranged in an upper portion of the fixation table 250 ; an annular blank holder (a second holder) 254 for supporting a periphery of the steel plate 212 ; and a die cushion mechanism 256 for elevating a blank holder 254 .
  • the blank holder 254 is arranged being opposed to the holder 240 . Therefore, the blank holder 254 pinches an end portion of the steel plate 212 together with the holder 240 .
  • the lower die 252 is used for press working when it pinches the steel plate 212 together with the upper die 238 .
  • a die face 252 a is provided which comes into contact with a lower face of the steel plate 212 .
  • This die face 252 a is formed into a shape corresponding to the aforementioned die face (the press forming face) 238 a .
  • the die cushion mechanism 256 includes: a plurality of pins 260 which penetrate the fixation table 250 and the attaching portion 252 b of the lower die 252 from the lower side and are fixed in a lower portion of the blank holder 254 ; a plate 262 for connecting lower end portions of these pins 260 ; a plurality of cylinders 264 for elevating the plate 262 ; and a second linear sensor 266 for detecting a position of the plate 262 and sending a signal of the position of the plate 262 to the control portion 216 .
  • the die cushion mechanism 256 includes: a hydraulic motor 268 for supplying hydraulic fluid to the cylinders 264 and for recovering hydraulic fluid from the cylinders 264 ; and a servo motor 270 for rotating the hydraulic motor 268 .
  • Rotation of the servo motor 270 is transmitted to the hydraulic motor 268 through a transmission portion 272 including a coupling, a reduction gear and so forth.
  • the hydraulic motor 268 is rotated either normally or reversely being driven by the servo motor 270 . Therefore, it is possible for the hydraulic motor 268 to selectively supply hydraulic fluid to the rod side or the cap side of the cylinder 264 . Due to the above constitution, while predetermined pressure control is being conducted, the periphery of the steel plate 212 is appropriately pushed by both the holder 240 and the blank holder 254 . Therefore, the generation of wrinkles can be prevented.
  • the control portion 216 includes: a press drive portion 216 a for driving and controlling the servo motor 224 while referring to signals sent from the encoder 224 a and the first linear sensor 236 ; and a die cushion drive portion 216 b for elevating the blank holder 254 by driving the servo motor 270 while referring to a signal sent from the second linear sensor 266 .
  • the press drive portion 216 a and the die cushion drive portion 216 b are connected with each other. Therefore, the press drive portion 216 a and the die cushion drive portion 216 b can be operated synchronously with each other. While the die cushion drive portion 216 b is being synchronized with the press drive portion 216 a , the die cushion drive portion 216 b can change an elevating speed of the blank holder 254 at predetermined time.
  • the press drive portion 216 a includes: a servo power source portion 304 to which electric power obtained from an electric power source 300 is supplied after the voltage has been raised by a transformer 302 ; and a servo amplifier 306 for driving the servo motor 224 with electric power adjusted by the servo power source portion 304 .
  • a servo amplifier 306 for driving the servo motor 224 with electric power adjusted by the servo power source portion 304 .
  • an amount of driving of the servo amplifier 306 is set while the software functional portion 308 is acting.
  • a large capacity condenser 310 is provided between the servo power source portion 304 and the servo amplifier 306 .
  • the die cushion drive portion 216 b includes: a servo power source portion 312 to which electric power is supplied from the power source 300 ; and a servo amplifier 314 for driving the servo motor 270 with electric power adjusted by the servo power source portion 312 .
  • An amount of driving of the servo motor 270 is set by the servo amplifier 314 while the software functional portion 316 is acting.
  • An electric current can be made to flow in both the positive and the negative direction in the servo power source portion 312 and the servo amplifier 314 .
  • the servo motor 270 is rotated by a load and generates electricity, it is possible to conduct a regeneration of electric power in which an electric current obtained by the generation of electric power is supplied to the press drive portion 216 a .
  • the thus regenerated electric power is stored in the large capacity condenser 310 and used for driving the servo motor 224 . Therefore, an increase in the power source capacity can be suppressed.
  • initial setting is made in step S 201 in FIG. 16 . That is, after the blank holder 254 has been raised to a predetermined position, the steel plate 212 , which has not been worked yet, is supported by the blank holder 254 . The upper die 238 is raised to an upper dead center.
  • step S 202 while the press drive portion 216 a is acting, the servo motor 224 is driven and rotated so as to lower the slider 232 .
  • the blank holder 254 is lowered while the die cushion drive portion 216 b is acting (step S 203 ).
  • the die cushion drive portion 216 b conducts pressure control so that the blank holder 254 can be lowered while the steel plate 212 is positively being held by an appropriate force lo generated by the blank holder 254 when a lower face of the steel plate 212 is pushed by the blank holder 254 . That is, the blank holder 254 is pushed by the holder 240 via the steel plate 212 . Therefore, the blank holder 254 is lowered while the steel plate 212 is being given an appropriate force.
  • the steel plate 212 is gradually pressed to a product shape by the upper die 238 and the lower die 252 .
  • the aforementioned regeneration may be made when electric power is generated by the servo motor 270 .
  • step S 204 according to a signal sent from the first linear sensor 236 , the press drive portion 216 a confirms whether or not positions of the holder 240 and the blank holder 254 have reached a predetermined pinch release position.
  • the program proceeds to step S 205 .
  • the descent is continued. This pinch release position is previously set at an appropriate position according to the press shape.
  • this pinch release position is set at a position a little higher than the bottom dead center, which is the lowest point in one stroke of the upper die 238 , at which the steel plate 212 is pressed by the die faces 238 a and 252 a .
  • the pinch release position is adjusted according to a deformation made by the press working. In the case where the plastic flow is small and press forming is conducted only by bending, distance xp (shown in FIG. 20B ) from the bottom dead center to the pinch release position is set at a very low value. In the case where the plastic flow is large and press forming is conducted by deep drawing, distance xp is set at a high value.
  • the pinch release position may be set at a position after the point of time of starting to press the steel plate 212 (refer to displacement x 3 of FIG. 20A ) and before the arrival at the bottom dead point.
  • step S 205 while the die cushion drive portion 216 b is acting, a lowering speed of the blank holder 254 is increased higher than a lowering speed of the holder 240 , so that the blank holder 254 can be separated from the holder 240 and the steel plate 212 . Due to the foregoing, a hold of the steel plate 212 is released and the steel plate 212 can be freely moved. Accordingly, a portion of the held steel plate 212 is made to plastically flow. Since press working is substantially finished at this point of time, a product shape of the steel plate 212 is mostly formed. Therefore, even when a reference of positioning, which is determined by holding, is not provided, there is no possibility that the shape of the product is collapsed.
  • the blank holder 254 gives a pushing force to the steel plate 212 . Therefore, the blank holder 254 maybe separated from the holder 240 by a small distance. Alternatively, as shown by the virtual line in FIG. 18 , a portion of the steel plate 212 maybe contacted with the blank holder 254 . Further, a force given by the pressure in the cylinder 264 may be sufficiently reduced by a predetermined decompressing mechanism.
  • step S 219 the press drive portion 216 a confirms whether or not the slider 232 has reached the bottom dead center referring to a signal sent from the first linear sensor 236 .
  • the program proceeds to step S 207 .
  • the slider 232 has not reached the bottom dead center, it continues to descend.
  • step S 207 the descent of the slider 232 and the descent of the blank holder 254 are stopped.
  • the steel plate 212 is pinched between the die face 238 a of the upper die 238 and the die face 252 a of the lower die 252 and press working has already been finished. Since the blank holder 254 is separated from the holder 240 , the steel plate 212 is released from pinching.
  • press working when both the dies are made to come most close to each other at the bottom dead center, a reduction of the wall thickness becomes the maximum in the process of press working. Therefore, since the steel plate 212 is released from being pinched at this point of time, it is possible to effectively prevent the generation of wrinkles and small wall thickness portions which are caused when the steel plate 212 is excessively strongly stretched.
  • step S 208 it is confirmed whether or not a predetermined period of time of stoppage has passed.
  • the program proceeds to step S 209 .
  • the slider 232 is stopped for the predetermined period of time at the bottom dead center, it becomes possible to give strain in the wall thickness direction. Therefore, a product shape of the steel plate 212 can be further stabilized.
  • step S 209 while the press drive portion 216 a is acting, the servo motor 224 is driven and rotated so as to raise the slider 232 . At this point of time, the blank holder 254 is left being stopped.
  • step S 210 it is confirmed whether or not the slider 232 has reached the panel conveyance position.
  • the program proceeds to step S 211 .
  • the descent of the slider 232 is continued.
  • step S 211 while the die cushion drive portion 216 b is acting, the blank holder 254 is raised. Due to the foregoing, the blank holder 254 is raised a little later than the slider 232 and contacted with an end portion of the steel plate 212 again so that the steel plate can be raised.
  • step S 212 the die cushion drive portion 216 b confirms whether or not the blank holder 254 has reached the panel conveyance position.
  • the program proceeds to step S 213 .
  • the blank holder 254 continues to be raised.
  • step S 213 a rise of the blank holder 254 is temporarily stopped. Then, the steel plate 212 , which has already been pressed, is conveyed to the next step, for example, a welding step, by a predetermined conveyance means.
  • step S 214 the die cushion drive portion 216 b raises the blank holder 254 again.
  • step S 215 the die cushion drive portion 216 b confirms whether or not the blank holder 254 has reached a working wait position.
  • the program proceeds to step S 216 .
  • the blank holder 254 has not reached the working wait position, the blank holder 254 continues to be raised.
  • step S 216 a rise in the blank holder 254 is stopped and the steel plate 212 , which has not been worked yet, is arranged at a predetermined position. In this connection, even in this period of time, the slider 232 continues to be raised.
  • step S 217 the press drive portion 216 a confirms whether or not the slider 232 has reached the top dead center referring to a signal sent from the first linear sensor 236 .
  • the slider 232 has not reached the top dead center, it continues to be raised.
  • the processing of this time shown in FIG. 16 is completed.
  • the slider 232 may be temporarily stopped for maintaining an appropriate relation with the cycle time of the other step. In the case where no influence is given to the other step, the slider 232 may not be temporarily stopped and the next steel plate 212 may be continuously worked.
  • the press drive portion 216 a and the die cushion drive portion 216 b may be independently operated while the mutual synchronization is being confirmed between them.
  • a series of the above working cycle is expressed by the time charts shown in FIGS. 20A and 20B .
  • the step numbers in the above processing are attached to corresponding portions.
  • displacement x of the slider 232 reciprocates between top dead center x 1 and bottom dead center x 2 .
  • the slider 232 stops for a predetermined period of time (a period of time between step S 205 and S 208 ).
  • the holder 240 reaches displacement x 3 at which the holder 240 comes into contact with an upper face of the steel plate 212 .
  • Displacement x 4 at the point of time of step S 211 is the panel conveyance position. That is, displacement x 4 at the point of time of step S 211 is the position corresponding to displacement y 3 of the blank holder 254 .
  • displacement y of the blank holder 254 stops at working wait position y 1 in the period of time corresponding to steps S 201 to S 203 and in the period of time after step S 215 .
  • step S 207 and step S 211 in which the slider 232 stops at bottom dead center x 2 the blank holder 254 is also stopped at the position of displacement y 2 .
  • steps S 203 and S 204 the blank holder 254 is lowered at the substantially same speed as that of the slider 232 .
  • steps S 204 and S 205 after the blank holder 254 has exceeded pinch release position y 4 the blank holder 254 is lowered at a speed a little higher than that of the slider 232 .
  • the blank holder 254 stops at panel conveyance position y 3 .
  • the press working method and the press working apparatus 210 of the second exemplary embodiment before the arrival at the bottom dead center at which both the dies are made to come close to each other, a pinch of the steel plate 212 conducted by the holder 240 and the blank holder 254 is released. Therefore, the steel plate 212 can be moved and it becomes possible to prevent the generation of wrinkles and small wall thickness portions which are caused when the steel plate 212 is excessively stretched.
  • the steel plate 212 is positively pinched by the holder 240 and the blank holder 254 . Therefore, the steel plate 212 is accurately positioned and it is possible to prevent wrinkles from being generated in the process of working.
  • the press working method and the press working apparatus 210 of the second exemplary embodiment can be suitably applied to press working except for deep drawing. Therefore, the press working method and the press working apparatus 210 of the second exemplary embodiment can be suitably applied to mass production.
  • the control portion 216 conducts controlling of making the upper die 238 come close to the lower die 252 and also conducts controlling of releasing a pinch of the steel plate, wherein controlling of making the upper die 238 come close to the lower die 252 and controlling of releasing a pinch of the steel plate are synthetically combined with each other. Therefore, press working can be accurately synchronized with releasing of a pinch of the steel plate.
  • press working method and the press working apparatus of the present invention are not limited to the above specific embodiments but variations may be made without departing from the spirit and scope of claim of the present invention.
US11/733,427 2006-04-14 2007-04-10 Press working method and press working apparatus Expired - Fee Related US7765848B2 (en)

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US20100275670A1 (en) 2010-11-04
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EP1844871A3 (fr) 2007-12-26
EP1844871A2 (fr) 2007-10-17
US7963141B2 (en) 2011-06-21
US20070240479A1 (en) 2007-10-18
CN101817043A (zh) 2010-09-01
EP1844871B1 (fr) 2010-02-24
EP2165781A8 (fr) 2010-06-02
EP2165781A1 (fr) 2010-03-24

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